Study of milling force variation in ultrasonic vibration-assisted end milling

Shen, Xuehui; Xu, Guo-Feng

doi:10.1080/10426914.2017.1364846

Cited by 23 publications

(7 citation statements)

References 22 publications

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“…Depth of cut and feed rate in both machining mode (VAM and non-VAM) are considered important parameters aside from spindle speed, af fecting the tool lifetime where it can fulfill the sustainable manufacturing principle [28]. The increase in the tool lifetime is mainly affected by the chosen parameter where it produces suitable cutting force during the machining process [29].…”

Section: Introductionmentioning

confidence: 99%

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

et al. 2022

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Vibration assisted machining (VAM) is one of the hybrid machining processes for improving the machined surface quality. VAM performance is mainly influenced by the combination of machining and vibration control parameters, where surface roughness value (Ra) became the benchmarking indicator. It is difficult to determine the optimum parameter combination to produce high precision products, especially for micro-milling, due to the interconnected correlation among parameters. The benefits of high-speed machining with VAM are high material removal rate and shorter machining time than low-speed machining. VAM operation at high-speed machining is still limited due to the high possibility of chatter occurrence. Therefore, this research aims to evaluate the 2D VAM resonant performance at low-speed and high-speed machining, operated at ultrasonic vibration and amplitude below one μm. The mathematical model and experimental evaluate the vibration effect based on machining mode, amplitude, and spindle speed variation. The mathematical modelling and experiment result complement each other, where the mathematical model can characterize the effect of resonant vibration, amplitude, and spindle speed increment on the tool path trajectory. The 2D resonant vibration at the feed direction causes interrupting cutting and transforms the tool path trajectory from linear to wavy. The mathematical model and experiment result show the dominant influence of spindle speed and feed rate on the toolpath trajectory and Ra, where low spindle speed and feed rate result in better machine surface roughness. The low-speed machining with VAM results in Ra value between 0.1–0.155 μm, which is below the high-speed machining result, between 0.2–0.38 μm

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Section: Introductionmentioning

confidence: 99%

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

et al. 2022

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“…The proposed predictive force model in ultrasonic vibration-assisted milling is validated through comparison to experimental measurements on Aluminum alloy 2A12 [21,22] values decrease by 39% in feed direction and 35% in cutting direction when the ultrasonic vibration is applied.…”

Section: Validation By Experimental Datamentioning

confidence: 99%

“…The machining forces are predicted by stress over contact area, and the coordinate transformation is applied to disassemble forces into feed, cutting, and axial directions. The force predictive model in ultrasonic vibration-assisted milling is validated through comparison of experimental measurements on Aluminum alloy 2A12 [21,22]. A sensitivity analysis is also conducted to estimate average forces under the effects of different cutting and ultrasonic parameters including axial depth of milling, feed per tooth, ultrasonic frequency, and spindle rotation frequency.…”

Section: Introductionmentioning

confidence: 99%

Force Prediction in Ultrasonic Vibration-Assisted Milling

Feng

Hsu

et al. 2019

Preprint

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Force reduction is one of the most important benefit of applying ultrasonic vibration on milling. However, most of studies so far are limited to experimental investigation. In the current study, an analytical predictive model on cutting forces in ultrasonic vibration-assisted milling is proposed. The three types of tool-workpiece criteria are considered based on the instantaneous position and velocity of tool center. Type I criterion indicates that there is no contact if the instantaneous velocity is opposite to tool rotation direction. Type II criterion checks whether the vibration displacement is larger than the instantaneous uncut chip thickness. Type III criterion considers the overlaps between current and previous tool paths due to vibration. If none of these criteria is satisfied, milling forces are nonzero. Then the calculation is performed by transforming milling and tool geometry configuration to orthogonal cutting at each instant. The orthogonal cutting forces are predicted through the exhaustive search of shear angle and calculation of shear flow stress on tool-chip interface. The axial force is then calculated based on tool geometry, and the milling forces in feed, cutting, and axial directions are calculated after coordinate transformation. The proposed predictive force model in ultrasonic vibration-assisted milling is validated through comparison to experimental measurements on Aluminum alloy 2A12. The predicted values are able to match the measured milling forces with high accuracy of average difference of 13.6% in feed direction and 13.8% in cutting direction.

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“…It will cause interrupting cutting that ignites an additional cooling period. The piezoelectric actuator is the main component of the device, which is operated by setting up the amplitude displacement and frequency [10][11][12][13] . Flexure or beam structure works with the actuator to achieve the designated displacement [14][15][16][17][18][19][20][21][22][23] .…”

Section: Introductionmentioning

confidence: 99%

The Influence of Flexure Variation to Vibration-Assisted Micro-Milling Device by Using Finite Element Analysis

Libyawati¹,

Kiswanto²,

Saragih³

et al. 2022

Evergreen

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This paper presents a compact method to predict the amplitude displacement and evaluate the influence of flexure structure on the vibration-assisted micro-milling device.The voltage load and flexure dimension variation are applied to the Finite Element model to obtain the predicted amplitude displacement. The simulation results show that amplitude displacement increases linearly along with the voltage load, but the influence of flexure thickness shows a varying trend on the amplitude displacement. The method can predict the device's amplitude displacement and movement pattern and is suitable for determining the optimum design for the vibration-assisted micro-milling device.

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Study of milling force variation in ultrasonic vibration-assisted end milling

Cited by 23 publications

References 22 publications

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

Force Prediction in Ultrasonic Vibration-Assisted Milling

The Influence of Flexure Variation to Vibration-Assisted Micro-Milling Device by Using Finite Element Analysis

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